Image display device, rear projection type screen used in image display device, Fresnel lens sheet, and method of making Fresnel lens sheet

ABSTRACT

A total reflecting prism portion is formed on an image generation source side of a Fresnel lens sheet which constitutes a rear projection type screen. The total reflecting prism portion is formed in an area in which the angle of incidence of a projection image projected from an optical part on the Fresnel lens sheet is at least about 40°. The total reflecting prism portion causes incident light to be outputted as output light at a predetermined output angle by a total reflection phenomenon after a first refraction phenomenon. Further, a refracting prism portion is formed on an image monitoring side of the Fresnel lens sheet. The refracting prism portion is formed in an area opposed to the portion where the total reflecting prism portion is not formed. The refracting prism portion causes incident light to be outputted as output light at a predetermined output angle by a second refraction phenomenon.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a divisional of U.S. patent application Ser. No. 10/857,647,filed May 28, 2004, which application claims priority from Japan PatentApplication No. 2003-322430, filed Sep. 16, 2003, and Japan PatentApplication No. 2003-308198, filed Sep. 1, 2003, the entire disclosureof which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to an image display device for projectingand displaying an image from an image generation source on a largerscale onto a rear projection type screen. The invention also relates tothe rear projection type screen used in the image display device, aFresnel lens sheet used in the screen, and a method of making theFresnel lens sheet.

An image display device which enlarges, using a projection lens, animage displayed on a small-sized image generation source and projectsthe image onto a rear projection type screen has recently been improvedremarkably in image quality. Incidentally, a cathode-ray tube or aliquid crystal display may be used as the small-sized image generationsource. The above-mentioned type of image display device has beenbecoming more and more popular for both home and business use.

The image display device uses a reflecting mirror for reflecting anenlarged image provided from a projection lens and conducting it to therear projection type screen, thereby decreasing the depth of the device.The rear projection type screen used in the image display device isusually provided with a Fresnel lens sheet and a lenticular lens sheet.The Fresnel lens sheet converts an enlarged projection image into lightwhich is substantially parallel or light which faces somewhat inwards.The lenticular lens sheet diffuses an image light horizontally of thescreen. In such a screen, to attain a further reduction in thickness ofthe image display device, the configuration described for example inWO/02/27399 (Patent Document 1) is known.

SUMMARY OF THE INVENTION

Problems to be solved by the present invention will now be describedwith reference to FIGS. 8 and 9. When image display devices having thesame screen size are compared with each other, the smaller the depth,the more advantages in point of weight, cost and installation space. Areflecting mirror 54 is used for decreasing the depth of an imagedisplay device in FIGS. 8 and 9. Making wider the field angle of aprojection lens 52 is also a means for decreasing the depth. However, alimit is encountered in widening the field angle of the lens. Supposethat an aspect ratio is 16:9 and a diagonal length is 65 inches. If theprojection distance is set at 700 mm or less, an image generation source51 and the projection lens 52 interfere with projection light.Consequently, a shadow area forms on a rear projection type screen 53.Thus, assume that an attempt is made to attain the reduction ofthickness by only widening of the field angle of the projection lens 52;a limit is encountered at a depth of 400 mm of an optical system in thecase where an aspect ratio is 16:9 and a diagonal length is 65 inches.Incidentally, a depth of the image display device is 450 mm in thiscase. In FIG. 8, an optical axis center of the projection lens 52 andthe center of the rear projection type screen 53 are aligned with eachother and an optical axis and the screen are set perpendicularly to eachother. However, by setting the optical axis center of the projectionlens 52 in the vicinity of a lower end of the rear projection typescreen 53, the image generation source 51 and the projection lens 52 nolonger interfere with projection light. This holds true even if theprojection distance is set at 700 mm or less. The rear projection typescreen illustrated in FIG. 9 is 16:9 in aspect ratio and 65 inches indiagonal length as in FIG. 8. However, the optical axis center of theprojection lens 52 is made coincident with the lower end of the screen53 and the projection distance is set at 500 mm. According to thearrangement illustrated in FIG. 9, the depth of the optical system is300 mm (the depth of the image display device is 350 mm). Thus, it ispossible to attain a further reduction of thickness.

As described above, thickness of the image display device can be reducedas follows. First, shorten the projection distance of the projectionlens 52. Then, set the optical axis center of the projection lens 52 ata position near the lower end of the rear projection type screen 53. Inthis case, however, the following problems newly arise.

In FIG. 9, the screen is 16:9 in aspect ratio and 65 inches in diagonallength. Thus, if the optical axis center of the projection lens 52 isset at a lower end center of the rear projection type screen 53, anincidence angle of image light incident on right and left upper ends ofthe screen 53 from the projection lens 52 is 65.2. FIG. 10 illustrates arelation between the angle of incidence of light on a screen in aconventional exit surface Fresnel lens and a reflection loss. From thesame graph, it is seen that the reflection loss of the screen is aslarge as 36% in case of the incidence angle of light being 65.2. If thethickness of the image display device is further reduced, the lossbecomes larger rapidly. This causes the problem that the image displaydevice becomes dark at right and left upper end portions of the screen.

The foregoing Patent Document I discloses a rear projection type screencontributing to the reduction in thickness of an image display device.In this screen, a refracting prism and a total reflecting prism areformed alternately on an incidence surface of light of a Fresnel lens.In addition, an exit surface of light is formed as a plane. In theconfiguration disclosed in the Patent Document 1, however, a refractingprism is formed on the light incidence surface of the Fresnel lens.Consequently, it causes the problem that efficiency becomes lower andthat a middle-area image (a doughnut-like area on the screen), which isan important image area, becomes dark.

The present invention has been accomplished in view of theabove-mentioned problems. It is an object of the invention to provide atechnique suitable for shortening the depth of an image display device.It is another object of the present invention to provide a techniquesuitable for shortening the depth of an image display device withoutgreatly impairing the quality (brightness) of an image displayed on ascreen.

For achieving the above-mentioned objects, an image display deviceaccording to the present invention is characterized in that a totalreflecting prism portion for outputting incident light as output lightof a predetermined output angle by a total reflection phenomenon after afirst refraction phenomenon is formed on an image generation source sideof a Fresnel lens sheet which constitutes a rear projection type screen.More specifically, the total reflecting prism portion is formed in anarea in which the angle of incidence of a projection image projectedfrom an optical part on the Fresnel lens sheet is at least apredetermined angle (for example, about 40). The image display device isalso characterized in that a refracting prism portion for outputting theincident light as output light of a predetermined output angle by asecond refraction phenomenon is formed in an area opposed to the portionwhere the total reflecting prism portion on an image monitoring side ofthe Fresnel lens is not formed.

In the present invention, the area where the refracting prism portion isformed is an area where light outputted from the total reflecting prismportion overlaps at least one pitch of the refracting prism portion.

In the present invention, a total reflection surface of the totalreflecting prism portion formed on the image generation source side ofthe Fresnel lens sheet which constitutes the rear projection type screenis made concave toward the image generation source side.

A method of making a Fresnel lens sheet according to the presentinvention is characterized in that a refracting prism portion and atotal reflecting prism portion are formed by thermocompression-molidng atransparent base such as polymethyl methacrylate or methylmethacrylate/styrene copolymer on both faces thereof simultaneously. Arefracting prism portion on an image monitoring side may be formed bythermocompression-molding and thereafter a total reflecting prismportion may be formed on the opposite side with use of anultraviolet-curing resin. A transparent base formed with a transparentultraviolet-curing resin layer having a total reflecting prism portionmay be fixed by bonding through an adhesive layer to the side oppositeto the side where the refracting prism portion is formed.

In the present invention, the refracting prism portion may be formedthroughout the whole surface on the image monitoring side of the Fresnellens sheet having the total reflecting prism portion. In the area inwhich the image generation source side of the Fresnel lens sheet is aflat plate, the prism angle of the refracting prism portion is set in amanner as follows. The prism angle becomes larger as the angle ofincidence of a projection image projected from the optical part on theFresnel lens sheet becomes larger. On the other hand, in the area fromthe position where the projection image passes the total reflectingprism portion formed on the image generation source side up to upper andlower ends, the prism angle of the refracting prism portion is setconstant or is made smaller as the angle of incidence becomes larger.

A predetermined incidence surface output angle at a start point of thetotal reflecting prism portion and a predetermined incidence surfaceoutput angle at a portion where the total reflecting prism portion isabsent (adjacent to the start point of the total reflecting prismportion) of the Fresnel lens sheet are set almost equal to each other.The former incidence surface output angle is obtained by a firstrefraction phenomenon and a total reflection phenomenon. The latterincidence surface output angle is obtained by a third refractionphenomenon.

A refractive index of the material of the total reflecting prism portionis set larger than that of the material of the base which constitutesthe Fresnel lens sheet. The incidence surface of the total reflectingprism portion is set so as to be inclined incidence surface output anglein the same direction as the total reflection surface of the totalreflecting prism portion.

A method of making a Fresnel lens sheet according to the presentinvention is characterized in that a refracting prism portion on animage monitoring side is formed by thermocompression-molding atransparent base, and thereafter a total reflecting prism portion isformed on the opposite side with use of an ultraviolet-curing resin. Thetransparent base is formed from polymethyl methacrylate or methylmethacrylate/styrene copolymer, for example. Further, a transparent baseformed with a transparent ultraviolet-curing resin layer having a totalreflecting prism portion may be fixed by bonding through an adhesive tothe side opposite to the side where the refracting prism portion isformed.

According to the present invention, it is possible to reduce thethickness of the image display device. Particularly, the thickness ofthe image display device can be reduced without greatly impairing thequality, e.g., brightness, of the image displayed on the screen.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially sectional perspective view showing an imagedisplay device according to a first embodiment of the present invention;

FIG. 2 is a schematic diagram showing the structure of a rear projectiontype screen 3 used in the first embodiment of the present invention;

FIG. 3 is a vertical sectional view of a Fresnel lens 6 used in thefirst embodiment shown in FIG. 2;

FIG. 4 is a vertical sectional view of the Fresnel lens 6 according tothe first embodiment, showing a boundary portion in which a totalreflecting prism portion 11 is formed on an image generation sourceside;

FIG. 5A is a vertical sectional view of the boundary portion where thetotal reflecting prism portion is formed. FIG. 5B is a verticalsectional view of a boundary portion where a total reflecting prismportion according to another example in the first embodiment is formed;

FIG. 6 is a diagram explaining how to fabricate the Fresnel lens sheetin the first embodiment;

FIG. 7 is a diagram explaining another example of a method offabricating the Fresnel lens sheet in the first embodiment;

FIG. 8 is a diagram showing a limit encountered in reducing thethickness of an optical system by widening the field angle of aprojection lens 52;

FIG. 9 is a diagram showing the reduction in thickness of the opticalsystem attained by shifting an optical axis center of the projectionlens 52 to a lower end center of a rear projection type screen 53;

FIG. 10 is a graph showing a relation between the angle of incidence oflight on the screen in a conventional exit surface Fresnel lens and areflection loss;

FIG. 11 is a schematic diagram showing the structure of a rearprojection type screen 3 according to a second embodiment of the presentinvention;

FIG. 12 is a vertical sectional view of a Fresnel lens sheet 6 used inthe second embodiment shown in FIG. 11;

FIG. 13 is a vertical sectional view of the Fresnel lens sheet 6 used inthe second embodiment, showing a boundary portion in which a totalreflecting prism portion 11 is formed on an image generation sourceside;

FIGS. 14A and 14B are graphs showing respectively a prism angle of arefracting prism portion 11 provided on a monitoring side of the Fresnellens 6 used in the second embodiment and a loss of light caused byreflection of the same Fresnel lens sheet;

FIGS. 15A and 15B are graphs showing respectively a prism angle of arefracting prism portion 11 formed on a monitoring side of a Fresnellens sheet 6 according to another example in the second embodiment and aloss of light caused by reflection of the same Fresnel lens sheet;

FIG. 16 is a graph showing a relation between a refractive index of atotal reflecting prism portion 10 and the angle of incidence of light onthe screen;

FIG. 17 is a graph showing a relation between the inclination of anincidence surface (surface c) of the total reflecting prism portion 10and the angle of incidence of light on the screen;

FIG. 18A is a vertical sectional view of a boundary portion in which thetotal reflecting prism portion 11 of the Fresnel lens sheet 6 in thesecond embodiment is formed.

FIG. 18B is a vertical sectional view of a boundary portion in which atotal reflecting prism portion of a Fresnel lens sheet according toanother example in the second embodiment is formed;

FIG. 19 is a diagram explaining a method of making a Fresnel lens sheetin the second embodiment;

FIG. 20 is a diagram explaining another example of a method of making aFresnel lens sheet in the second embodiment; and

FIG. 21 is a diagram explaining a further example of a method of makinga Fresnel lens in the second embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment

An image display device according to a first embodiment of the presentinvention will be described in detail hereinunder with reference to theaccompanying drawings.

FIG. 1 is a partially sectional perspective view of the image displaydevice. An image generation source 1 includes a projection typecathode-ray tube, a reflection or transmission type liquid crystalpanel, and an image modulator such as a display element provided with aplurality of very small mirrors. The image generation source 1 displaysa small-sized image. A projection lens 2 projects the image onto a rearprojection type screen

Since the projection distance is generally long, a reflecting mirror 4is disposed in a related optical path for diminishing the depth of theimage display device. These components are fixed at respectivepredetermined positions in the interior of a case 5.

FIG. 2 is a schematic diagram showing the structure of the rearprojection type screen 3 used in the first embodiment. An enlargedprojection image (not shown) projected in the direction of arrow b isconverted to light which is substantially parallel or light which facessomewhat inwards while passing through a Fresnel lens sheet 6. Then, theconverted light is incident on a lenticular lens sheet 7. As shown inthe same figure, the lenticular lens sheet 7 has a shape such thatplural lenticular lenses having a longitudinal direction vertically ofthe screen are arranged horizontally of the screen. The lenticular lenssheet 7 functions to diffuse the image light horizontally of the screen.Black stripes 8 extending vertically of the screen are formed on an exitsurface of the lenticular lens sheet 7. The black stripes 8 absorbextraneous light which is incident from the exit side of the screen.Further, a diffusing material 9 is kneaded into the lenticular lenssheet 7. The diffusing material 9 diffuses the image light horizontallyand vertically of the screen. In the first embodiment illustrated inFIG. 2, a total reflecting prism portion 10 (first prism) is formed inan area (first area) on the image generation source side of the Fresnellens. The first area is an area in which the angle of incidence of lightprojected in arrow b direction on the Fresnel lens sheet is at least apredetermined angle, e.g., about 40 or more. The total reflecting prismportion 10 allows incident light to be outputted as output light at apredetermined output angle by a total reflection phenomenon after afirst refraction phenomenon. The image generation source side of theFresnel lens sheet is formed as a plane portion free of the totalreflecting prism portion in an area (second area). The second area is anarea in which light of a projection image is incident at an anglesmaller than the aforesaid predetermined angle. Further, a refractingprism portion (second prism portion) 11 is formed in an area opposed tothe second area on an image monitoring side of the Fresnel lens. Therefracting prism portion 11 allows incident light to be outputted asoutput light at a predetermined output angle by a second refractionphenomenon. The total reflecting prism portion 10 is convexed(projected) toward the image generation source side, while therefracting prism portion 11 is convexed (projected) toward the imagemonitoring side.

The operation of the total reflecting prism portion 10 will now bedescribed with reference to FIG. 3. FIG. 3 is a vertical sectional viewof the Fresnel lens sheet 6 according to the first embodiment shown inFIG. 2. In FIG. 3, a vicinity of a left (right) upper end of the rearprojection type screen 3 shown in FIG. 1 is illustrated on a largerscale. Arrows indicate the direction of light. As shown in FIG. 3, thetotal reflecting prism portion 10 is formed on the image generationsource side of the Fresnel lens sheet 6. The monitoring side is in aplane shape. Light emitted from the image generation source side isincident on surface c (incidence surface) of the total reflecting prismportion 10 and is totally reflected by surface d (total reflectionsurface). Then, the reflected light exits nearly horizontally to themonitoring side. Although FIG. 3 is a vertical sectional view of a flatplate portion of the monitoring side, a refracting prism portion isformed in the area opposed to the area where the total reflecting prismportion is not formed. A boundary portion of the two is formed so thatoutput light from the total reflecting prism portion overlaps at leastone pitch of the refracting prism portion. The reason for this will bestated below with reference to FIG. 4.

FIG. 4 is a vertical sectional view of the Fresnel lens sheet 6according to the first embodiment. A boundary portion between the totalreflecting prism portion 10 on the image generation source side and therefracting prism portion 11 on the image monitoring side is shown on alarger scale. As shown in FIG. 4, the area (second area) on the imagegeneration source side of the Fresnel lens 6 is a flat portion (planeportion) 12 where the total reflecting prism portion 10 is not formed.The second area is an area on which the image light is incident at apredetermined incidence angle (40) or less. If the angle of incidence onthe Fresnel lens sheet 6 of a projection image projected from theoptical part on the image generation source side is small, it isimpossible to form the total reflecting prism portion 10. Therefore, inan area in which the angle of incidence of the projection image on theFresnel lens sheet 6 is small, the image generation source side is flatand the refracting prism portion 11 is formed on the monitoring side,like the conventional exit surface Fresnel lens. Thus, in the Fresnellens sheet 6 according to the present invention, a sudden change occursfrom the flat portion on the image generation source side to the portionwhere the total reflecting prism portion 10 is formed. The imagegeneration source side and the monitoring side of the Fresnel lens aremolded using separate molds. Thus, it is difficult to position bothsides into complete coincidence due to expansion and contraction causedby a temperature difference. Therefore, when the image generation sourceside changes from the flat portion to the portion where the totalreflecting prism portion 10 is formed, this change must be preventedfrom appearing in image. That is, it is necessary to use means for suchprevention. In the Fresnel lens sheet 6 according to the firstembodiment shown in FIG. 4, the boundary portion is formed so that lightoutputted from the total reflecting prism portion 10 overlaps at leastone pitch of the refracting prism portion 11. That is, on the imagemonitoring side of the Fresnel lens sheet 6, the greater part of thearea opposed to the first area is planar. A partial area (the portionopposed to the total reflecting prism portion 10 positioned near theboundary between the first area and the planar second area) is providedwith the refracting prism portion 11 at one to several pitches, orseveral ten pitches, or more. Thus, a part of the total reflecting prism10 and a part of the refracting prism portion 11 overlap each other inthe thickness direction of the Fresnel lens sheet 6.

Light incident on surface c of the total reflecting prism portion 10 istotally reflected by surface d. Then, the reflected light exits as it isif the monitoring side of the Fresnel lens sheet 6 is flat. However, asshown in the figure, when light is incident on the refracting prismportion 11, it is totally reflected by the refracting prism portion 11.Then, the reflected light exits outwards and disappears from themonitoring side. Since the image light is not visible from themonitoring side, the image is broken off. However, there no longer isany such an image defect as the image source side and the monitoringside of the Fresnel lens 6 are dislocated from each other withconsequent absence of image light and appearance of a black circulararc. Besides, even if the image is broken off, the amount thereof isonly a displacement quantity between both faces. Since the production iscarried out with a high accuracy, it is impossible for the image to bemarkedly broken off.

Next, another example in the first embodiment will be described withreference to FIGS. 5A and 5B. FIG. 5A is a vertical sectional view ofthe portion where the total reflecting prism portion 10 of the Fresnellens sheet 6 in the first embodiment is formed. This portion is the sameas in FIG. 4, but is large in the angle of incidence of the projectionimage on the Fresnel lens sheet 6. In the same figure, only lightpassing portions are hatched. The same reference numerals and marks asin FIG. 4 denote the same components and portions as in FIG. 4. In theportion shown in FIG. 4 where the angle of incidence of the projectionimage on the Fresnel lens 6 is small, output light from the Fresnel lenscontinues substantially without break. However, in the portion shown inFIG. 5A where the angle of incidence of the projection image on theFresnel lens 6 is large, output light from the Fresnel lens iscompletely separated into an output light portion and a non-output lightportion. The presence of such a light-free portion causes the generationof moiré between the total reflecting prism portion and the lenticularlens sheet 7 in the rear projection type screen 3 or pixels in the imagegeneration source. Thus, it is necessary to use a certain means forpreventing the occurrence of moiré. FIG. 5B is a vertical sectional viewof a portion where a total reflecting prism portion 14 of a Fresnel lenssheet according to another example in the first embodiment is formed. InFIG. 5B, only light passing portions are hatched. In the same figure,the numeral 14 denotes a total reflecting prism portion formed on animage generation source side of a Fresnel lens sheet 13. In the Fresnellens sheet 13 according to the present invention shown in FIG. 5B, lightis incident from surface e of the total reflecting prism portion 14 andis totally reflected by surface f. The reflected light expands becausethe surface f is molded concavely to the image generation source side.As a result, image light continues without break on the monitoring side.Consequently, moiré does not occur between the total reflecting prismportion 14 on the image generation source side and the lenticular lenssheet 7 in the rear projection type screen 3 or pixels in the imagegeneration source.

Generally, molding of a prism portion of a Fresnel lens sheet is carriedout using an ultraviolet-curing resin. However, in the case where prismportions are provided on both faces of a Fresnel lens sheet likeaccording to the present invention, only one face can be molded becausethe ultraviolet-curing resin does not transmit ultraviolet light. TheFresnel lens sheet according to the present invention can be fabricatedin the following manner.

The first method is as follows. Both faces of a transparent base arethermocompression-molded simultaneously using two opposed molds. Thetransparent base is formed from polymethyl methacrylate or methylmethacrylate/styrene copolymer, for example. The two opposed moldscorrespond to a refracting prism portion and a total reflecting prismportion. Since an ultraviolet-curing resin is not used in this method,the Fresnel lens sheet having prism portions on both faces thereofaccording to the present invention can be fabricated easily.

FIG. 6 illustrates how to fabricate the Fresnel lens sheet according tothe first embodiment. The refracting prism portion 11 is formed bymolding on a transparent base 15 which constitutes the Fresnel lenssheet 6. A transparent ultraviolet-curing resin layer 16 is bonded tothe face of the transparent base 15 on which the refracting prismportion 11 is not formed. The total reflecting prism portion 10 isformed by molding on the transparent ultraviolet-curing resin layer 16.More specifically, the transparent base 15 such as polymethylmemthacrylate or methyl methacrylate/styrene copolymer is subjected tothermocompression molding to form the refracting prism portion 11 on theimage monitoring side. Thereafter, the total reflecting prism portion 10is formed on the opposite side of the refracting prism portion 11 withuse of an ultraviolet-curing resin. In the example shown in FIG. 6, theultraviolet-curing resin adheres not only to the total reflecting prismportion 10 but also to the plane portion to form the transparentultraviolet-curing resin layer 16.

FIG. 7 illustrates another example of a Fresnel lens sheet fabricatingmethod in the first embodiment. A first transparent ultraviolet-curingresin layer 19 is bonded to a first transparent base 18 whichconstitutes a Fresnel lens sheet 17. A refracting prism portion 20 isformed on the first transparent ultraviolet-curing resin layer 19. Asecond transparent ultraviolet-curing resin layer 21 is provided on thefirst transparent base 18 on the side where the refracting prism portion20 is not formed. A total reflecting prism portion 22 is formed on thesecond transparent ultraviolet-curing resin layer 21. More specifically,the second transparent ultraviolet-curing resin layer 21 having thetotal reflecting prism portion 22 is formed on a second transparent base23 by an ultraviolet curing method. Thereafter, the total reflectingprism portion 22 is fixed through the second transparent base 23 to thefirst transparent base 18 by bonding with use of an adhesive layer 24.

As the material of the first transparent base 18 which constitutes theFresnel lens sheet 17, polymethyl methacrylate or methylmethacrylate/styrene copolymer may be used, for example. Likewise, asthe material of the second transparent base 23 on which the secondultraviolet-curing resin layer 21 having the total reflecting prismportion 22 is formed, polyethylene terephthalate may be used. In thiscase, polyethylene terephthalate has been subjected to a surfacetreatment for facilitating the bonding thereto of the ultraviolet-curingresin. A highly transparent acrylic adhesive is used as the adhesivelayer 24. In the above description, the second transparentultraviolet-curing resin layer 21 having the total reflecting prismportion 22 is bonded using the adhesive layer 24. The same effect can beattained even if the first transparent ultraviolet-curing resin layer 19having the refracting prism portion 20 is bonded using an adhesive layer24.

According to the first embodiment of the present invention describedabove, an optical axis center of the projection lens is set to aposition near the lower end of the rear projection type screen for thepurpose of decreasing the depth of the image display device. As aresult, the screen incidence angle of image light incident on both rightand left upper end portions of the screen may become excessively large.However, the present invention can suppress a reflection loss of thescreen. Further, it is possible to diminish the moiré phenomenon whichoccurs in the Fresnel lens sheet. Thus, according to the presentinvention, it is possible to provide an image display device which isbright up to both right and left upper end portions of the screen.

Second Embodiment

A second embodiment of the present invention will be described belowwith reference to the accompanying drawings.

FIG. 11 is a schematic diagram showing the structure of a rearprojection type screen 3 according to the second embodiment. An enlargedprojection image (not shown) projected in the direction of arrow b isconverted to light which is substantially parallel or light whichsomewhat faces inwards while passing through a Fresnel lens 6. Then, theconverted light is incident on a lenticular lens sheet 7. As shown inthe same figure, the lenticular lens sheet 7 has a shape such thatplural lenticular lenses having a longitudinal direction vertically ofthe screen are arranged horizontally of the screen. The lenticular lenssheet 7 functions to diffuse the image light horizontally of the screen.Black stripes 8 extending vertically of the screen are formed on an exitsurface of the lenticular lens sheet 7 to absorb extraneous light whichis incident from the exit side of the screen. A diffusing material 9 iskneaded into the lenticular lens sheet 7 to diffuse the image lighthorizontally and vertically of the screen. The second embodimentillustrated in FIG. 11 is characterized in that a total reflecting prismportion 10 is formed on an image generation source side of the Fresnellens sheet. More specifically, the total reflecting prism portion 10 isformed in an area in which the angle of incidence of light projected inarrow b direction on the Fresnel lens sheet is at least about 40 ormore. The total reflecting prism portion 10 allows incident light to beoutputted at a predetermined incidence surface output angle by a totalreflection phenomenon after a first refraction phenomenon. The secondembodiment is also characterized in that a refracting prism portion 11is formed throughout the whole surface on an image monitoring side ofthe Fresnel lens sheet.

The operation of the total reflecting prism portion 10 will now bedescribed with reference to FIG. 12. FIG. 12 is a vertical sectionalview of the Fresnel lens sheet 6 according to the second embodimentshown in FIG. 11. In FIG. 12, a vicinity of a left (right) upper end ofthe rear projection type screen 3 shown in FIG. 11 is illustrated on alarger scale. Arrows in the figure indicate the direction of light. Asshown in FIG. 12, the total reflecting prism portion 10 is formed on theimage generation source side of the Fresnel lens sheet 6. The refractingprism portion 11 is formed on the monitoring side of the Fresnel lenssheet. Light emitted from the image generation source side is incidenton surface c (incidence surface) of the total reflecting prism portion10 and is totally reflected by surface d (total reflection surface).Then, the reflected light is refracted by the refracting prism portion11 and exits nearly horizontally to the monitoring side. The angle oflight after the total reflection can be made nearly horizontal byenlarging the angle of surface d. However, in the present invention, theangle of surface d is set small to keep large the angle of light afterthe total reflection. The light is then refracted by the refractingprism portion 11 on the exit side. Thereafter, the light is outputtednearly horizontally to the monitoring side. The reason for this will bestated below with reference to FIG. 13.

FIG. 13 is a vertical sectional view of the Fresnel lens sheet 6according to the second embodiment. As shown in FIG. 13, a predeterminedarea on the image generation source side of the Fresnel lens sheet 6 isa flat portion (plane portion) where the total reflecting prism portion10 is not formed. More specifically, the above-mentioned predeterminedarea is an area on which image light is incident at a predeterminedincidence angle (40) or less. If the angle of incidence on the Fresnellens sheet 6 of a projection image projected from the optical part onthe image generation source side is small, it is impossible to form thetotal reflecting prism portion 10. Therefore, in an area in which theangle of incidence of the projection image on the Fresnel lens sheet 6is small, the image generation source side is flat and the refractingprism portion is formed on the monitoring side, like the conventionalexit surface Fresnel lens. Thus, in the Fresnel lens sheet 6 accordingto the present invention, a sudden change occurs from the flat portionon the image generation source side to the portion where the totalreflecting prism portion 10 is formed. Since the image generation sourceside and the monitoring side of the Fresnel lens sheet 6 are usuallymolded separately, the sudden change must be prevented from appearing inimage. In the Fresnel lens sheet 6 according to the present inventionshown in FIG. 13, angles α and β are set almost equal to each other. Theangle α is an angle of light incident on the refracting prism portion 11after incidence from surface c of the total reflecting prism portion 10and after subsequent total reflection by surface d. The angle β is anangle of light incident on the refracting prism portion 11 afterincidence from a flat portion 12 and after subsequent refraction. Bysetting the two angles almost equal to each other, the angle of lightincident on the refracting prism portion 11 is almost constant.Accordingly, even if the image generation source side and the monitoringside of the Fresnel lens sheet 6 are somewhat displaced from each other,the angle of light outputted from the Fresnel lens sheet 6 is keptconstant.

Next, with reference to FIGS. 14A, 14B and FIGS. 15A, 15B, a descriptionwill be given about a prism angle of the refracting prism portion 11formed on the monitoring side of the Fresnel lens 6 according to thesecond embodiment. FIG. 14A shows a prism angle of the refracting prismportion 11 formed on the monitoring side of the Fresnel lens sheet 6according to the second embodiment. FIG. 14B shows the loss of lightcaused by reflection of the Fresnel lens sheet 6. In both graphs, theangle of incidence of light on the screen is plotted along the axis ofabscissa. As shown in FIG. 14A, from the point corresponding to anincidence angle of light on the screen of 67°, the prism angle of therefracting prism portion 11 becomes constant at 76°. This can beattained by forming the total reflecting prism portion 10 on theincidence surface from this point. The loss of light of the Fresnel lenssheet 6 according to this embodiment becomes almost constant as in FIG.14B. The loss of light does not undergo a sudden increase unlike thereflection loss of the conventional Fresnel lens sheet referred toabove. FIGS. 15A shows a prism angle of a refracting prism portion 11 ofa Fresnel lens sheet 6 according to another example in the secondembodiment. FIG. 15B shows the loss of light caused by reflection of thesame Fresnel lens sheet 6. In both graphs, the angle of incidence oflight on the screen is plotted along the axis of abscissa. As shown inFIG. 15A, the prism angle of the refracting prism portion 11 becomesgradually smaller from the point corresponding to an incidence angle oflight on the screen of 67°. This can be attained by enlarging the angleof surface d of the total reflecting prism portion 10 gradually fromthis point. At this time, the loss of light of the Fresnel lens sheet 6becomes smaller gradually with the start point of the total reflectingprism portion 10 as a peak, as shown in FIG. 15B. The example shown inFIGS. 5A and 5B usually applies, but in such an image display deviceincluding a dark peripheral portion, the peripheral portion can bebrightened by adopting the example of FIGS. 15A and 15B. In the presentinvention, the prism angle of the refracting prism portion 11 formed onthe monitoring side of the Fresnel lens sheet 6 can be set freely in theranges shown in FIGS. 14A, 14B and FIGS. 15A, 15B and therefore, it ispossible to make design in accordance with the image display deviceconcerned.

In FIGS. 14A, 14B and FIGS. 15A, 15B, the angle of incidence of light onthe screen at the position where the total reflecting prism portion 10is formed is as large as 67°. The loss of light is also as larger as35%. Means for diminishing these values will now be described withreference to FIGS. 16 and 17. FIG. 16 shows a relation between therefractive index of the total reflecting prism portion 10 and the angleof incidence of light on the screen. It is seen from FIG. 16 that theangle of incidence of light on the screen can be made small byincreasing the refractive index of the total reflecting prism portion10. In this case, the refractive index of the total reflecting prismportion 10 should be made at least larger than the refractive index ofthe material of the base which constitutes the Fresnel lens sheet. FIG.17 illustrates a relation between the inclination of the incidencesurface (surface c) of the total reflecting prism portion 10 and theangle of incidence of light on the screen. As to the inclination of theincidence surface (surface c) of the total reflecting prism portion 10,the same direction as the total reflection surface (surface c) isindicated with a negative sign. It is seen from FIG. 16 that the angleof incidence of light on the screen can be made small by setting theinclination of the incidence surface (surface c) of the total reflectingprism portion 10 in a negative direction. Generally, however, if theinclination of the incidence surface (surface c) of the total reflectingprism portion 10 is made negative, it becomes extremely difficult toeffect manufacture. As to this manufacturing method, a description willbe given later.

Another example in the second embodiment will now be described withreference to FIGS. 18A and 18B. FIG. 18A is a vertical sectional view ofthe total reflecting prism portion 11 of the Fresnel lens sheet 6according to the second embodiment. The figure is the same as in FIG.13. In FIG. 18A, only light passing portions are hatched. The samereference numerals and marks as in FIG. 13 represent the same componentsand portions. As is apparent from FIG. 18A, the light is incident fromthe flat portion 12 free of the total reflecting prism portion 10 on theimage generation source side. The light is then incident without breakon the refracting prism portion 11 formed on the monitoring side.However, as to the light incident from the total reflecting prismportion 10 formed on the image generation source side, there exists alight-free portion in the refracting prism portion 11 formed on themonitoring side. The presence of such a light-free portion poses noproblem if the following condition is satisfied. That is, the totalreflecting prism portion 10 on the image generation source side and therefracting prism portion 11 on the monitoring side are located at justthe same pitch without displacement. However, even a slight displacementbetween the two would lead to the occurrence of moiré. FIG. 18B is avertical sectional view of a total reflecting prism portion according toanother example in the second embodiment. In the figure, only lightpassing portions are hatched. In FIG. 18A, the numeral 14 denotes atotal reflecting prism portion formed on an image generation source sideof a Fresnel lens sheet 13. The numeral 15 denotes a refracting prismportion formed on a monitoring side. The numeral 16 denotes a flatportion where the total reflecting prism portion 14 on the imagegeneration source side is not formed. In the Fresnel lens sheet 13according to the present invention shown in FIG. 18B, light is incidenton surface e of the total reflecting prism portion 14 and is totallyreflected at surface f. Since the surface f is molded concavely to theimage generation source side, the reflected light spreads and eventuallybecomes incident without break on the refracting prism portion 15 formedon the monitoring side. Therefore, even if the total reflecting prismportion 14 on the image generation source side and the refracting prismportion 15 on the monitoring side are slightly dislocated from eachother, moiré does not occur.

Generally, molding of a prism portion of a Fresnel lens sheet is carriedout using an ultraviolet curing resin. However, in the case where prismportions are formed on both faces of a Fresnel lens sheet as in thepresent invention, it is only one face that can be subjected to molding,because the ultraviolet curing resin does not transmit ultravioletlight. The Fresnel lens sheet according to the present invention can befabricated in the following manner.

FIG. 19 illustrates how to fabricate the Fresnel lens sheet according tothe second embodiment. A refractory prism portion 11 is formed bymolding on a transparent base 17 which constitutes the Fresnel lenssheet 6. A transparent ultraviolet curing resin layer 18 is bonded tothe face of the transparent base 17 on which face the refracting prismportion 11 is not formed. A total reflecting prism portion 10 is formedby molding on the transparent ultraviolet curing resin layer 18. Morespecifically, the refracting prism portion 11 is formed on the imagemonitoring side by thermocompression-bonding the transparent base 17such as polymethyl methacrylate or methyl methacrylate/styrenecopolymer. Thereafter, the total reflecting prism portion 10 is formedon the opposite side with use of an ultraviolet curing resin. In theexample shown in FIG. 19, the ultraviolet curing resin adheres not onlyto the total reflecting prism portion 10 but also to the plane portionto form a transparent ultraviolet curing resin layer 18.

FIG. 20 illustrates another example of a method of making a Fresnel lenssheet according to the second embodiment. A first transparentultraviolet curing resin layer 21 is bonded to a first transparent base20 which constitutes a Fresnel lens 19. A refracting prism portion 22 isformed on the first transparent ultraviolet curing resin layer 21. Asecond transparent ultraviolet curing resin layer 23 is formed on theface of the first transparent base on which face the refracting prismportion 22 is not formed. A total reflecting prism portion 24 is formedon the second transparent ultraviolet curing resin layer 23. The secondtransparent ultraviolet curing resin layer 23 having the totalreflecting prism portion 24 is formed on a second transparent base 25 byan ultraviolet curing method. The layer 23 is then fixed by bonding tothe first transparent base 20 through an adhesive layer 26.

As the material of the first transparent base 20 which constitutes theFresnel lens sheet 19, polymethyl methacrylate or methylmethacrylate/styrene copolymer may be used, for example. Polyethyleneterephthalate may be used as the material of the second transparent base25 for the second transparent ultraviolet curing resin layer 23 havingthe total reflecting prism portion 24. In this instance, polyethyleneterephthalate has been subjected to a surface treatment to facilitatebonding of the ultraviolet curing resin. A highly transparent acrylicadhesive may be used as the adhesive layer 26. The second transparentultraviolet curing resin layer 23 having the total reflecting prismportion 24 is bonded using the adhesive layer 26 in the abovedescription. However, even if the first transparent ultraviolet curingresin layer 21 having the refracting prism portion 22 is bonded usingthe adhesive layer 26, the same effect can be attained.

FIG. 21 illustrates a further example of a method of making a Fresnellens sheet according to the second embodiment. A first transparentultraviolet curing resin layer 29 having a refracting prism portion 30is bonded to a first transparent base 28 which constitutes a Fresnellens 27. A second transparent ultraviolet curing resin layer 31 havingtotal reflecting prism portions 32 is formed on the first transparentbase 28 on the side opposite to the side where the refracting prismportion 30 is formed. More specifically, the second transparentultraviolet curing resin layer 31 having the total reflecting prismportions 32 is formed on a second transparent base 33 by an ultravioletcuring method. The layer 31 is thereafter fixed by bonding to the firsttransparent base 28 through an adhesive layer 34. In the example shownin FIG. 21, the second transparent ultraviolet curing resin layer 31having the total reflecting prism portions 32 is divided into four. Thesecond transparent ultraviolet curing resin layer 31, the secondtransparent base 33 and the adhesive layer 34 are omitted in the portionwhere the total reflecting prism portions 32 are not formed. Thisexample is effective when the positions where the total reflecting prismportions 32 are formed are only the corner portions of the Fresnel lenssheet 27. The second transparent ultraviolet curing resin layer 31having the total reflecting prism portions 32 and which is to be bondedto the first transparent base 28 may be the same at all of the fourcorner portions. The layer 31 at the four corner portions may besubjected to trimming where required. Further, the second transparentultraviolet curing resin layer 31 having the total reflecting prismportion 32 is bonded at all of the four corners in this example.However, the positions where the total reflecting prism portions 32 areto be formed may be two in each of upper, lower, right, and leftportions or may be an arbitrary one corner in accordance with what isrequired of the optical system used. By thus dividing the secondtransparent ultraviolet curing resin layer 31 having the totalreflecting prism portions 32 as in FIG. 21, the following effect can beattained. That is, manufacture can be relatively facilitated even if theinclination of the incidence surface (surface c) of the total reflectingprism portion 10 is set negative as noted earlier. All that is requiredat the time of mold release is a mere movement toward a curvature centerof the Fresnel lens. Suppose that the inclination of the incidencesurface (surface c) of the total reflecting prism portion 10 is a littlelarge in the negative direction. Even so, it is easy to effect moldrelease as long as the second transparent ultraviolet curing resin layer31 and the second transparent base 33 are each formed of a flexiblematerial.

According to the second embodiment, as set forth above, the optical axiscenter of the projection lens is set near the lower end of the rearprojection type screen for diminishing the depth of the image displaydevice. Consequently, the angle of incidence of image light on the lightand left upper end portions of the screen becomes too large. Even so, itis possible to suppress a reflection loss of the screen. It is alsopossible to diminish the moiré phenomenon which occurs in the Fresnellens sheet. Thus, according to the present invention, it is possible toobtain an image display device which is bright up to the right and leftupper end portions of the screen.

1. A rear projection type screen on which an image generated from animage generation source is projected, said rear projection type screencomprising: a Fresnel lens sheet disposed at least on the imagegeneration source side; and a diffusion sheet disposed on an imagemonitoring side to diffuse image light to the image monitoring side,said Fresnel lens sheet including a first prism which is convex towardthe image generation source side and a second prism which is convextoward the image monitoring side, wherein said first prism includes atotal reflection surface provided in a first area on the imagegeneration source-side face of said Fresnel lens sheet, with light ofthe projection image being incident on the first area at an angle of notsmaller than a predetermined incidence angle, said total reflectionsurface totally reflecting the light incident on the first area andconducting the reflected light to the image monitoring side of saidFresnel lens sheet, a second area on said Fresnel lens sheet on whichlight of the projection image is incident at an angle of smaller thanthe predetermined incident angle is in a plane shape, and said secondprism is formed in an area opposed to said second area on the imagemonitoring-side face of said Fresnel lens sheet and functions to refractand output light which has entered second area and passed through saidFresnel lens sheet.
 2. A rear projection type screen according to claim1, wherein said predetermined incidence angle is about 40 degrees.
 3. Arear projection type screen according to claim 1, wherein an areaopposed to said first area on the image monitoring-side face of saidFresnel lens sheet is in a plane shape.
 4. A rear projection type screenaccording to claim 3, wherein said second prism is formed in part of thearea opposed to said first area on the image monitoring-side face ofsaid Fresnel lens so as to be opposed to said first prism which ispositioned near a boundary of said first and second areas.
 5. A rearprojection type screen on which light generated from an image generationsource is projected, comprising: a Fresnel lens sheet having a firstprism formed on the image generation source side and a second prismformed on an image monitoring side; and a lenticular lens sheet disposedon the image monitoring side of said Fresnel lens sheet, wherein saidfirst prism is formed in an area on the image generation source side ofsaid Fresnel lens sheet on which the light is incident at an angle ofincidence of not smaller than a predetermined angle of incidence, andsaid first prism includes an incidence surface on which the light isincident and a total reflection surface which totally reflects the lightincident from said incidence surface and conducts it to said secondprism.